Remanufactured part core return process and system

ABSTRACT

One aspect of the present invention is a computer-implemented method for processing remanufactured part cores. The method includes receiving manufactured part core inventory information. The inventory information can include an inventory forecast and an inventory level for a number of parts. The method further includes receiving a part number of a part to be processed. The part to be processed is a member of the number of parts. The method further includes receiving one or more business rules for processing the part to be processed. A part disposition for the part to be processed is determined based on the remanufactured part core inventory information, the one or more business rules and the part number.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 11/532,668filed Sep. 18, 2006, which is incorporated by reference in its entirety.

BACKGROUND

1. Technical Field

One aspect of the present invention generally relates to aremanufactured part core return process and system.

2. Background Art

Remanufactured part programs rely on the cheap availability of qualityused parts, otherwise referred to as cores, to be remanufactured.Brokers and junkyards collect cores in high volume industries, forexample, the automotive industry. However, this supply is oftenunreliable and costly. Oftentimes, the core shipment includes severalcores having one or more defects, e.g. rusting, denting and/orcorrosion. Moreover, in many cases, the availability of cores forremanufacturing operations is an issue. Many new part production plantsroutinely sell excess production or defective parts (which are oftensold to and used by competitors), rather than holding these parts forlater use as cores in remanufacturing operations, thereby increasingmanufacturing costs.

In attempting to solve the core availability and quality issues, somepart sellers have implemented reverse distribution processes whichtypically require several distributors, in some cases, hundreds ofdistributors, of new parts to pick up and return old cores. Customers ofthe part sellers willingly return old cores in order to obtain a refundof deposits, which were collected when they purchased new parts.

While partially addressing the core availability and quality issues,managing the return and crediting processes, especially through hundredsof return points, is relatively expensive. On some parts, the relativehigh cost of collecting and returning cores precludes the use of aremanufacturing program. To lower remanufacturing costs, somemanufacturers enforce core pickup rules on their distributors, whichtypically require the distributors to pick up only non-defective coresfrom customers, and/or negotiate the amount of deposit refund to paycustomers depending on the condition of the cores. These pickup ruleprograms may cause dissatisfaction in retail outlets, which havedifficulty collecting refunds, and in distribution outlets, which arecaught in the middle. Some manufacturers pass increased core handlingcosts of the cumbersome return process on to customers. In recent years,only 70% of United States automotive dealers on average were satisfiedwith the core return practices of the automotive OEMs.

Moreover, the shear number of distributors needed for a typical reversedistribution process produces relatively high handling andtransportation costs.

In light of the foregoing, a method and system for returningremanufactured part cores is needed. What is also needed is acomputer-implemented method and system for returning remanufactured partcores.

SUMMARY

One aspect of the present invention is a method and system forprocessing remanufactured part cores. Another aspect of the presentinvention is a computer-implemented method and system for processingremanufactured part cores.

According to a first embodiment of the present invention, acomputer-implemented method for processing a remanufactured part core isdisclosed. The method includes receiving remanufactured part coreinformation, which can include an inventory forecast and an inventorylevel for a number of parts. The method also includes receiving a partnumber of a part to be processed. The part to be processed is a memberof the number of parts. The method also includes receiving one or morebusiness rules for processing the part. The part disposition for thepart is determined based on the remanufactured part core inventoryinformation, the one or more business rules and the part number.

The method can further include transmitting the part disposition so thatit can be relied upon to process the part. The method can furtherinclude transmitting the part number from a remote location using aportable electronic device. The part disposition can be selected fromthe group consisting of holding the part, shipping the part, scrappingthe part and selling the part.

The method can further include generating a claim receipt including thepart number and the part disposition. The method can further includedetermining a core deposit credit value for the part to be processed.The method can further include receiving a grade for the part to beprocessed.

The determining step can include determining the part disposition forthe part to be processed based on the manufactured part core inventoryinformation, the one or more business rules, the part number and thepart grade.

According to another embodiment of the present invention, a computersystem is disclosed that has a central processing unit (CPU) forexecuting machine instructions and a memory for storing machineinstructions that are to be executed by the CPU. Machine instructionswhen executed by the CPU implement the following functions: receiving apart number of a part to be processed; receiving a part disposition forthe part based on the remanufactured part core inventory information,one or more business rules and the part number; and transmitting thepart disposition so that it can be relied upon to process the part. Thecomputer can be a portable electronic device: e.g. a portable digitalassistant (PDA). The part disposition can be selected from the groupconsisting of holding the part, shipping the part, scrapping the partand selling the part.

The functions to be executed by the CPU can further include generating aclaim receipt including the part number and the part disposition;determining a core deposit value for the part to be processed; and/orreceiving a grade for the part to be processed.

According to yet another embodiment of the present invention, acomputer-implemented method for processing remanufactured part cores isdisclosed. The method can include receiving one or more business rulesrelating to the disposition of a part, receiving a part number of a partto be processed, and determining a disposition for the part to beprocessed based on the one or more business rules and the part number.The one or more business rules can be related to inventory managementand/or part handling. The method can further include transmitting thepart number from a remote location using a portable electronic device,e.g. a portable digital assistant (PDA).

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention which are believed to be novel areset forth with particularity in the appended claims. The presentinvention, both as to its organization and manner of operation, togetherwith further objects and advantages thereof, may best be understood withreference to the following description, taken in connection with theaccompanying drawings which:

FIG. 1 is a computer system architecture for processing remanufacturedpart cores according to one embodiment of the present invention;

FIG. 2 is a flowchart depicting the movement part cores through thereturn process according to one embodiment of the present invention;

FIG. 3 is a flowchart depicting the steps of a part core processingmethod according to one embodiment of the present invention; and

FIG. 4 is a flowchart depicting a method for generating a dispositioncode according to one embodiment of the present invention.

DETAILED DESCRIPTION

FIG. 1 is a computer system architecture 10 for processingremanufactured part cores according to one embodiment of the presentinvention. The computer system architecture 10 includes presentationtier 12, server tier 14, and back-end application tier 16.

The presentation tier 12 includes a number of personal digital assistant(PDA) devices 18 and workstation computer 20, which can be part of anexternal computer system, represented by dotted rectangle 22. In atleast one embodiment, an external computer system is defined as a systemthat is outside the control of an internal computer system. Forinstance, the external computer system can be a vendor computer systemand the internal computer system can be an OEM computer system.

The PDA device can be placed in an accompanying cradle to synchronizethe data residing on the PDA device with the data stored on workstationcomputer 20. In at least one embodiment, the PDA devices are configuredto execute an application for processing remanufactured part cores,otherwise referred to as a part core application. The part coreapplication can be embedded in computer software loadable onto the PDAdevice. The part core application includes a number of functions forcarrying out part core processing steps as contemplated by the presentinvention. It should be appreciated that the part core application caninclude one or more remote function calls for calling and executingfunctions residing on a remote computer system, e.g. computers that area part of the server tier 14. In this way, the part core applicationdoes not have to include all the functions locally necessary to performthe processing, thereby saving memory space on the PDA device. In atleast one embodiment, mobile users, e.g. truck drivers picking up partcores, utilize the PDA device.

The server tier 14 includes support computer 24, data server computer 26and website server computer 28. The server tier 14 can function toprovide storage of data uploaded from the PDA device and the ability totransmit data to and receive data from the PDA device.

In at least one embodiment, support computer 24 includes a generatingmodule 30 for generating one or more part core applications and aninstallation module 32 for installing the generated applications. In atleast one embodiment, the installation module 32 can be configured towrite an installation application to a compact disc (CD) for installingthe generated applications on workstation computer 20. Once theapplications are installed on the workstation computer, the applicationscan be installed on the PDA device through a cradle synchronizingprocess. The support computer 24 can be part of an internal computersystem, signified by dash-dotted rectangle 34. Data server computer 26can include a database 36, which can include the following data: partcore data, customer data, and/or PDA transaction data. Non-limitingexamples of customers include dealers, e.g. vehicle dealers, and serviceentities, e.g. vehicle service entities, respectively. The data server26 can also be part of an internal computer system, represented bydash-dotted rectangle 38. The data server 26 can be configured totransmit data from database 36 to support computer 24 through one-waycommunication line 40.

Website server computer 28 can include one or more web page files 42.The website server computer 28 can serve web pages based on the datacontained in the one or more web page files 42. Computer 28 can be partof an internal business to business (B2B) computer system, representedby dashed rectangle 44. Website server computer 28 and data servercomputer 26 can be in communication with each other through two-waycommunication line 46. For instance, a served web page may request auser to input information relating to part core processing. Thisinformation can be transmitted through communication line 46 and storedin database 36. As another non-limiting example, part data residing indatabase 36 can be transmitted to website server 28, which serves one ormore web pages containing the part information. Website server computer28 can transmit served web pages to workstation computer 20 throughone-way communication line 46 and Internet 48. In at least oneembodiment, the served web pages can be formatted for display on theserver of the PDA device.

The back-end application tier 16 includes a business server computer 50,which can be part of an internal computer system, represented bydash-dotted rectangle 52. Tier 16 can function to store data uploadedfrom the PDA devices into the corresponding internal business computersystem. This storage function can be executed through a batch process.Business server computer 50 can be in two-way communication with dataserver 26 through communication line 54.

The communication lines identified above can be intranet-adaptablecommunication lines, for example, a dedicated line, a satellite link, anEthernet link, a public telephone network, a private telephone network,and hybrids thereof. The communication lines can also beintranet-adaptable. Examples of suitable communication lines include,but are not limited to, public telephone networks, public cablenetworks, and hybrids thereof.

Turning to FIG. 2, a flowchart 100 depicting the movement of part coresthrough the return process according to one embodiment of the presentinvention is provided. Customer 102 has a number of part cores 103 atone or more sites that need to be processed, e.g. picked up and returnedto the warehouse 106. The warehouse can be controlled or operated by anOEM, e.g. a vehicle OEM. A non-limiting example of a customer is adealer, e.g. a vehicle dealer, or a service entity, e.g. a vehicleservice entity. A pickup agent 104 arrives at customer 102 to processthe part cores. One non-limiting example of such a process is depictedin FIG. 3. A non-limiting example of a pickup agent 104 is a truckdriver that has a contractual obligation with the warehouse 106 to pickup and return part cores 103. In certain embodiments, the part coreprocess includes generating a disposition label for each part core,picking up each part core, and returning each part core to thewarehouse. A non-limiting example of pickup agent is a truck driver.

The pickup agent 104 delivers the picked up part cores to a warehouse106. In at least one embodiment, the disposition label is utilized toidentify how the part core should be further processed. Non-limitingexamples of further processing includes holding the part core (108),sending the part core to a supplier (110), scrapping the part core(112), and/or selling the part core (114). Advantageously, the suppliercan track inventory levels; part field attrition; customer attrition;optimize inventory levels; forecast breakdowns; and monitor cash flowsbased on the information produced and/or obtained during part coreprocessing.

Turning to FIG. 3, a flowchart 200 depicting one embodiment forprocessing part cores is provided. In at least one embodiment, one ormore of these steps is performed at one or more customer sites by apickup agent using a PDA device, although other users and/or computerdevices can be used to accomplish one or more of these steps. Moreover,it should be appreciated that the steps can be rearranged, modified andomitted according to the implementation of the present invention.

In block 202, a customer code is input. In at least one embodiment, thecustomer code can be used to identify the customer possessing the corethat will be picked up. In at least one embodiment, the pickup agentinputs the customer code into a PDA device.

In block 204, the pickup agent visually identifies a container whichhouses a part core to be processed. In at least one embodiment, thecontainer may include a number of part cores to be processed. In atleast one embodiment, a tag is affixed to the container for identifyingwhether the part core is a retail or warranty part core. These tags areotherwise referred to as retail tags or warranty tags.

If, upon visual identification, the container has a warranty tag, thepickup agent performs the steps on the warranty side of flowchart 200.If the container has a retail tag, the pickup agent performs the stepson the retail side of flowchart 200. This decision point is representedby decision block 206 of flowchart 200.

Continuing onto the retail side of flowchart 200, the pickup agent usesthe PDA device to scan the container for a part core identification (ID)code, according to block 208.

In decision block 210, the ability of the PDA device to scan the ID codeis tested. If the PDA device is unable to scan the ID code, then thecontainer is opened (block 212) to visually inspect the part core insidethe container. In block 214, the pickup agent calls a function that isavailable through a part core application loaded on the PDA device toaid in identifying the part core. The function can include the abilityto display parts on the PDA screen so that the pickup agent can obtain avisual match. Upon generating a visual match, the function can retrievethe ID code based on the match information. Moreover, the function caninclude the ability to prompt the pickup agent with a number ofidentification rules to aid in identifying the part core.

If the PDA device is able to scan the ID code, then the PDA applicationsearches one or more part catalogs, which can reside on database 36, forthe part core based on the ID code. In decision block 216, the abilityto locate the part in the one or more part catalogs is tested. If thepart core cannot be located in the one or more catalogs, then theidentify function is executed (block 214). If by performing block 214,the product cannot be identified (decision block 218), then the productis not picked up (block 220). If the product can be identified by block214, then the block 222 is performed.

In block 222, the pickup agent assigns a grade to the part core. In atleast one embodiment, an alpha grading system having product grades inthe range of “A” (highest grade) to “F” (lowest grade) is utilized toidentify the value of the core to the remanufacturing process and/orsale of the core. In at least one embodiment, “A” is a new, unused corewith no defects such that it can be sold as-is, “D” is a typical usedcore (the default code for most returned cores) to be remanufactured,and “F” is a severely damaged core to be scrapped.

In at least one embodiment, the pickup agent inputs one or moreexception codes for the part core into the PDA device. Non-limitingexamples of exception codes include dis-assembled cores, cores missingcomponents, cores not drained of lubricants.

In block 224, the part core grade is input into the PDA device by thepickup agent, via a web page displayed on the PDA screen, for example.

In block 226, the repair order (RO) number is input into the PDA deviceby the pickup agent, via a web page displayed on the PDA screen, forexample.

In block 228, a disposition code for the part core is generated. FIG. 4is a flowchart 300 depicting a method for generating the dispositioncode according to one embodiment of the present invention. According toFIG. 4, the part number 302, the part grade 304 and part core inventoryinformation is input into a business rules engine 306, which iscomprised of a number of business rules. The business rules engine usesthe input 302, 304 and/or 306 and the number of business rules togenerate a disposition code 310. Non-limiting examples of part coreinventory information includes forecasting data, current inventorylevels, manufacturing attrition, suggested input levels, and lead time.In at least one embodiment, the business rules include: placing numericlimits on total system-wide core inventory wherein excess inventory canbe scrapped or sold, maintaining inventory levels at suppliers and/orwarehouse reserve locations, prioritizing disposition code based on coregrade, prioritizing override factor(s) to be considered (e.g. based oncustomer code or an override table) and handling invalid input data(e.g. no forecast or no identified supplier).

In at least one embodiment, the disposition code is selected from anumber of numeric codes. For instance, the numeric codes can be “1”,“2”, “3” and “4”. The description associated with “1” can be hold theproduct at the warehouse. The description associated with “2” can bescrap the product. The description associated with “3” can be sellingthe product. The description associated with “4” can be shipping theproduct to a supplier.

Turning back to FIG. 3, a disposition label containing the dispositioncode is generated by the PDA device (block 230). If the disposition codeis “2”, “3” or “4”, the label also includes the disposition descriptionand supplier information, e.g. supplier code and/or name and address.

According to decision block 232, if one or more unprocessed containersexists at the current customer site, then the applicable steps offlowchart 200 are carried out on the next unprocessed container,starting with the first step downstream from circle label “B”, i.e. thestep in block 204.

Turning to the warranty side of flowchart 200, if the container has awarranty tag, the container is scanned with the PDA device for thewarranty tag information (block 246).

If the PDA device is unable to scan the warranty tag on the container(decision block 248), then the pickup agent can input the information onthe warranty tag into the PDA device (block 250).

In block 252, the information on the warranty tag is captured on theclaim receipt, which can be stored on the PDA device. The next step onthe warranty side is to check for more containers, as set forth in block232.

Once all of the containers are processed, a claim/return order isgenerated by the PDA device (block 234). In at least one embodiment,data on the claim/return order includes the date, pickup agent, customercode, name and address, a detailed listing of the core part numberspicked up, the deposit to be credited for each core picked up, the totalcredit amount, and a claim reference number.

In block 236, a claim receipt is printed from the PDA device. In atleast one embodiment, the claim receipt includes a core deposit creditthat the customer will receive. The amount of core deposit credit to bereceived can be determined based on the part number, the customer's ID,and one or more of the business rules. In at least one embodiment, thecustomer signs the printed receipt and retains a copy for its files.

In decision block 238, the pickup agent identifies whether morecustomers having unprocessed containers exist. If yes, then theapplicable steps of flowchart 200 carried out for the unprocessedcontainers at the next customer site, starting with the first stepdownstream from circle label “A”, i.e. the step in block 202.

Alternatively, the pickup agent ends the trip and returns to thewarehouse (block 240). In block 242, the PDA device is placed in itscradle, thereby transmitting the data obtained during the part coreprocessing to the data server computer 26. The uploaded data can be usedto generate an inventory receipt, including the disposition code and anyexception codes, and to process customer credits. In at least oneembodiment, one or more of the web page files 42 can be updated, forexample, daily, with customer core deposit credit information. These webfiles can be accessed as web pages by the customer through a secure webportal. Once the truck arrives at the warehouse 106, the processedcontainers are unloaded (block 244). In at least one embodiment, all ofthe warranty tag containers are picked up and unloaded at the warehouse.

As required, detailed embodiments of the present invention are disclosedherein. However, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. Therefore, specific functional details describedherein are not to be interpreted as limiting, but merely as arepresentative basis for the claims and/or as a representative basis forteaching one of ordinary skill in the art to variously employ thepresent invention.

While the best mode for carrying out the invention has been described indetail, those familiar with the art to which this invention relates willrecognize various alternative designs and embodiments for practicing theinvention as defined by the following claims.

What is claimed:
 1. A computer having a central processing unit (CPU)for executing machine instructions and a memory for storing machineinstructions that are to be executed by the CPU, the machineinstructions when executed by the CPU implement the following functions:receiving remanufactured part core inventory information which includesan inventory forecast and an inventory level for a number of parts;receiving one or more business rules which includes a placement of anumeric limit on a total part core inventory; receiving informationidentifying an unprocessed part which is a member of the number ofparts; receiving reusability grade, identifying whether the identifiedunprocessed part is reusable or non-reusable; determining whether a partis reusable or non-reusable based on the received reusability grade;determining whether the reusable, unprocessed part or non-reusable,unprocessed part is an excess inventory part or a non-excess inventorypart based on the one or more business rules; and depending on whetherthe reusable, unprocessed part or non-reusable, unprocessed part is anexcess inventory part or a non-excess inventory part, determining a partdisposition for the reusable, unprocessed part or non-reusable,unprocessed part based on the remanufactured part core inventoryinformation and the part identifying information, wherein if theunprocessed part is a non-excess inventory part, the part disposition isselected from the group consisting of holding the part or shipping thepart, and wherein if the unprocessed part is an excess inventory part,the part disposition is selected from the group consisting of sellingthe part or scrapping the part.
 2. The computer of claim 1 wherein thecomputer is a portable electronic device.
 3. The computer of claim 2wherein the portable electronic device is a portable digital assistant(PDA).
 4. The computer of claim 1 wherein the functions further comprisegenerating a claim receipt including the part identifying informationand the part disposition.
 5. The computer of claim 4 wherein the partidentifying information is a part number.
 6. The computer of claim 1wherein the functions further comprise determining a core deposit creditvalue for the part with a part disposition.
 7. The computer of claim 1wherein the reusability grade is based on a scaled rating of the partwith respect to its reusability.
 8. The computer of claim 1 wherein theone or more business rules further include information relating to parthandling, wherein the functions further include utilizing a plurality ofdisposition codes to identify the manner in which a part is handledbased on the part handling information.
 9. The computer of claim 1wherein the functions further comprise: generating part processing databased on the executed functions; and transmitting the part processingdata for processing of customer core deposit credit information.
 10. Thecomputer of claim 9 wherein processing customer core deposit creditinformation includes updating a data repository of customer core depositcredit information.
 11. A non-transitory computer-readable mediumcomprising executable instructions for: receiving remanufactured partcore information including inventory forecast and level for a number ofparts; receiving a business rules including a numeric limit on core partinventory; receiving a part number identifying an unprocessed one of thenumber of parts and reusability grade for the unprocessed part;identifying the part as reusable or non-reusable based on the grade;determining whether the reusable, unprocessed part or non-reusable,unprocessed part is an excess inventory part or a non-excess inventorypart based on the business rules; and depending on whether a reusable,unprocessed part or non-reusable, unprocessed part is an excessinventory part or a non-excess inventory part, determining a partdisposition for the reusable, unprocessed part or non-reusable,unprocessed part based on the remanufactured part core inventoryinformation and the part identifying information, wherein if theunprocessed part is a non-excess inventory part, the part disposition isselected from the group consisting of holding the part or shipping thepart, and wherein if the unprocessed part is an excess inventory part,the part disposition is selected from the group consisting of sellingthe part or scrapping the part.
 12. The computer-readable medium ofclaim 11 further comprising executable instructions for displaying aweb-based user interface for receiving the reusability grade.
 13. Thecomputer-readable medium of claim 11 further comprising executableinstructions for: generating a disposition code based on the partdisposition; and presenting the disposition code.
 14. Thecomputer-readable medium of claim 13 wherein the executable instructionsfor presenting the disposition code includes executable instructionsfor: generating a part disposition label for the part; and printing thepart disposition code on the label so that it can be relied upon toprocess the part.
 15. The computer-readable medium of claim 13 furthercomprising executable instructions for presenting a part dispositiondescription associated with at least one part disposition code.
 16. Acomputer-program product for processing remanufactured part cores, thecomputer-program product stored in a computer-readable medium andexecuting on the computer-readable medium and comprising instructionsfor: receiving remanufactured part core inventory information, theinventory information including an inventory forecast and an inventorylevel for a number of parts; receiving part identifying information foran unprocessed part from the number of parts; receiving one or morebusiness rules including a placement of a numeric limit on a total partcore inventory; receiving a reusability grade for the unprocessed part;determining that the unprocessed part is reusable or non-reusable basedon the reusability grade; determining whether the reusable, unprocessedpart or non-reusable, unprocessed part is an excess inventory part or anon-excess inventory part based on the business rules; if the reusable,unprocessed part is excess inventory, determining a part disposition ofselling the part or scrapping the part; if the reusable, unprocessedpart is non-excess inventory, determining a part disposition of holdingthe part or shipping the part; and if the unprocessed part isnon-reusable, determining a part disposition of scrapping the part. 17.The computer-program product of claim 16 further comprising instructionsfor assigning a part disposition identifier to the unprocessed partbased on the part disposition.
 18. The computer-program product of claim17 wherein the identifier is a numeric code.
 19. The computer-programproduct of claim 18 further comprising instructions for prioritizingdisposition codes based on reusability grade.